Methods and Apparatuses for Making Absorbent Articles Having Contoured Belts

ABSTRACT

The present disclosure relates to methods and apparatuses for assembling disposable pant diapers having contoured elastic belts. During the assembly process, opposing end regions of chassis are connected with the elastic belts in the form of first and second continuous elastic laminates. The chassis are then folded to place the elastic laminates into a facing relationship. The inner longitudinal edges of one or both the elastic laminates are then cut to define a contoured shape. Discrete pieces of trim material may be removed from one or both the elastic laminates, and the first and second continuous elastic laminates are cut in the cross direction to form discrete pant diapers. In some configurations, a single knife both removes the trim material and cuts the elastic laminates in cross direction. And in some configurations, a first knife removes the trim material and a second knife cuts the elastic laminates in cross direction.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/129,852, filed on Sep. 13, 2018, which is a divisional of U.S.application Ser. No. 14/559,942, filed on Dec. 4, 2014, which claims thebenefit of U.S. Provisional Application No. 61/918,087, filed Dec. 19,2013, which are all incorporated by reference herein.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods for makingelastic belts for diapers.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and/or otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. In some cases,individual components created from advancing web or webs are combinedwith other individual components created from other advancing web orwebs. Webs of material and component parts used to manufacture diapersmay include: backsheets, topsheets, leg cuffs, waist bands, absorbentcore components, front and/or back ears, fastening components, andvarious types of elastic webs and components such as leg elastics,barrier leg cuff elastics, stretch side panels, and waist elastics. Oncethe desired component parts are assembled, the advancing web(s) andcomponent parts are subjected to a final knife cut to separate theweb(s) into discrete diapers or other absorbent articles.

Some diaper pant embodiments are configured with a chassis connectedwith front and back elastic belts, wherein opposing end regions of thefront and back belts are connected with each other at side seams. Insome instances, the elasticity of the front and back belts is removed inregions where the chassis connects with the belts. Thus, in someconverting configurations adapted to assemble such diaper pants,stretched elastic strands are glued between two continuous nonwoven websto form an elastic laminate. Regions of the elastic strands may then beintermittently deactivated along the length of the elastic laminate bycutting the elastic strands. Subsequent to deactivating the elasticstrands, the elastic laminate may be subjected to additional handlingand converting operations.

In some instances, the diaper pants include front and back elastic beltsare configured with shaped or contoured inner edges that extend alongthe leg openings of the diaper. Thus, in some converting configurationsadapted to assemble such diaper pants, stretched elastic strands areglued between two continuous nonwoven webs to form an elastic laminate.The elastic laminate may then be cut along the machine direction in asinusoidal or curved path to form continuous lengths of the front andback elastic belts, which are then subjected to additional handling andconverting operations.

However, cutting elastic laminate in a curved path may weaken thelaminate, making the laminate relatively more likely to tear, and/or mayotherwise result in control and handling difficulties associated withdifferential stretch characteristics within the laminate. In addition,such shaping of the front and back elastic belts relatively early in theassembly process may also require relatively precise phasing andregistration processes in order to ensure that the shaped areas of thebelts are positioned in the desired locations of the assembled product.Consequently, it would be beneficial to provide methods and apparatusesthat are configured to provide a shaped belts relatively late in theassembly process so as to minimize the handling of the shaped elasticlaminates; and/or assemble the elastic laminate in such a way tomaximize the aesthetic appearance of the laminate when placed in anassembled product.

SUMMARY OF THE INVENTION

The present disclosure relates to methods and apparatuses for assemblingdisposable pant diapers having contoured elastic belts. During theassembly process, opposing end regions of chassis are connected with theelastic belts in the form of first and second continuous elasticlaminates. The chassis are then folded to place the elastic laminatesinto a facing relationship. The inner longitudinal edges of one or boththe elastic laminates are then cut to define a contoured shape. Discretepieces of trim material may be removed from one or both the elasticlaminates, and the first and second continuous elastic laminates are cutin the cross direction to form discrete pant diapers. In someconfigurations, a single knife both removes the trim material and cutsthe elastic laminates in cross direction. And in some configurations, afirst knife removes the trim material and a second knife cuts theelastic laminates in cross direction.

In some embodiments, a method for assembling disposable pant diapers,each pant diaper including a chassis having a first end region and anopposing second end region separated from each other by a centralregion, and having a longitudinal axis and a lateral axis, the chassisincluding: a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet, includes the steps of: advancinga first continuous elastic laminate along a machine direction, the firstcontinuous elastic laminate having an outer longitudinal edge and aninner longitudinal edge defining a substantially constant width, W1, ina cross direction; advancing a second continuous elastic laminate alongthe machine direction, the second continuous elastic laminate having anouter longitudinal edge and an inner longitudinal edge defining asubstantially constant width, W2, in the cross direction, wherein thefirst continuous elastic laminate is separated in the cross directionfrom the second continuous elastic laminate to define a gap between theinner longitudinal edge of the first continuous elastic laminate and theinner longitudinal edge of the second continuous elastic laminate;depositing a plurality of chassis spaced apart from each other along themachine direction across the gap and onto the first continuous elasticlaminate and the second continuous elastic laminate, wherein the firstend regions of each chassis are connected with the first continuouselastic laminate, and the second end regions of each chassis areconnected with the second continuous elastic laminate; folding eachchassis along the lateral axis to position the first continuous elasticlaminate into a facing relationship with the second continuous elasticlaminate and defining uncovered regions of the second continuous elasticlaminate intermittently spaced between the chassis along the machinedirection and having a width, W3, extending in the cross directiondefined by a distance extending between the inner longitudinal edge ofthe first continuous elastic laminate and the inner longitudinal edge ofthe second continuous elastic laminate; removing discrete pieces of trimmaterial from the uncovered regions of the second continuous elasticlaminate; and cutting the first and second continuous elastic laminatesin the cross direction to form discrete pant diapers.

In some embodiments, a method for assembling disposable pant diapers,each pant diaper including a chassis having a first end region and anopposing second end region separated from each other by a centralregion, and having a longitudinal axis and a lateral axis, the chassisincluding: a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet, includes the steps of: advancinga first continuous elastic laminate along a machine direction, the firstcontinuous elastic laminate having an outer longitudinal edge and aninner longitudinal edge; advancing a second continuous elastic laminatealong the machine direction, the second continuous elastic laminatehaving an outer longitudinal edge and an inner longitudinal edge,wherein the first continuous elastic laminate is separated in the crossdirection from the second continuous elastic laminate to define a gapbetween the inner longitudinal edge of the first continuous elasticlaminate and the inner longitudinal edge of the second continuouselastic laminate; depositing a plurality of chassis spaced apart fromeach other along the machine direction across the gap and onto the firstcontinuous elastic laminate and the second continuous elastic laminate;folding each chassis along the lateral axis to position the firstcontinuous elastic laminate into a facing relationship with the secondcontinuous elastic laminate and defining uncovered regions of the secondcontinuous elastic laminate intermittently spaced between the chassisalong the machine direction and having a width, W, extending in thecross direction defined by a distance extending between the innerlongitudinal edge of the first continuous elastic laminate and the innerlongitudinal edge of the second continuous elastic laminate; advancingthe first continuous elastic laminate in the facing relationship withthe second continuous elastic laminate through a nip defined between acutting roll and an anvil roll wherein the cutting roll includes a bladehaving a distal edge extending in the cross direction and the machinedirection; and pressing the distal edge of the blade against the firstcontinuous elastic laminate and the second continuous elastic laminatein the nip to remove discrete pieces of trim material from the uncoveredregions of the second continuous elastic laminate and to cut the firstand second continuous elastic laminates in the cross direction to formdiscrete pant diapers.

In some embodiments, a method for assembling disposable pant diapers,each pant diaper including a chassis having a first end region and anopposing second end region separated from each other by a centralregion, and having a longitudinal axis and a lateral axis, the chassisincluding: a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet, includes the steps of: advancinga first continuous elastic laminate along a machine direction, the firstcontinuous elastic laminate having an outer longitudinal edge and aninner longitudinal edge defining a substantially constant width in across direction; advancing a second continuous elastic laminate alongthe machine direction, the second continuous elastic laminate having anouter longitudinal edge and an inner longitudinal edge defining asubstantially constant width in the cross direction; depositing aplurality of chassis spaced apart from each other along the machinedirection onto the first continuous elastic laminate and the secondcontinuous elastic laminate; folding each chassis along the lateral axisto position the first continuous elastic laminate into a facingrelationship with the second continuous elastic laminate to form acontinuous length of absorbent articles; advancing the continuous lengthof absorbent articles in a first direction to a knife roll;simultaneously cutting the first and second continuous elastic laminatesin the cross direction to form discrete pant diapers and cuttingdiscrete pieces of trim material from at least one of the firstcontinuous elastic laminate and the second continuous elastic laminate;wrapping the discrete pant diapers partially around the knife roll;advancing the discrete pant diapers in a second direction from the kniferoll while holding the discrete pieces of trim material on the kniferoll, wherein the second direction is different from the firstdirection; and removing the discrete pieces of trim material from theknife roll.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front perspective view of a diaper pant.

FIG. 1B is a rear perspective view of a diaper pant.

FIG. 2 is a partially cut away plan view of the diaper pant shown inFIGS. 1A and 1B.

FIG. 3A is a cross-sectional view of the diaper pant of FIG. 2 takenalong line 3A-3A.

FIG. 3B is a cross-sectional view of the diaper pant of FIG. 2 takenalong line 3B-3B.

FIG. 4 is a schematic side view of a converting apparatus adapted tomanufacture pre-fastened, pant diapers.

FIG. 5A is a view of a continuous length of chassis assemblies from FIG.4 taken along line A-A.

FIG. 5B1 is a view of a discrete chassis from FIG. 4 taken along lineB1-B1.

FIG. 5B2 is a view of a discrete chassis from FIG. 4 taken along lineB2-B2.

FIG. 5C is a view of continuous lengths of advancing front and back sidepanel material from FIG. 4 taken along line C-C.

FIG. 5D is a view of multiple discrete chassis spaced from each otheralong the machine direction MD and connected with each other by thefront and back side panel material from FIG. 4 taken along line D-D.

FIG. 5E is a view of folded multiple discrete chassis with the front andback side panel material in a facing relationship from FIG. 4 takenalong line E-E.

FIG. 5E1 is a detailed view of a bonded overlapped area from FIG. 5E.

FIG. 5E2 is a detailed view of a bonded overlapped area from FIG. 5E.

FIG. 5E3 is a detailed view of a bonded overlapped area from FIG. 5E.

FIG. 5E4 is a detailed view of a bonded overlapped area from FIG. 5E.

FIG. 5F is a view of two discrete absorbent articles advancing themachine direction MD from FIG. 4 taken along line F-F.

FIG. 5F1 is a detailed view of a bonded overlapped area from FIG. 5F.

FIG. 6 is a perspective schematic view of a cutting apparatus.

FIG. 7 is a partial plan view of a knife roll.

FIG. 8 is a schematic side view of a cutting apparatus.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

“Radial” means a direction running from the center of a drum toward adrum outer circumferential surface.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed byvarious techniques including, but not limited to, joining togetherportions of the article using any refastenable and/or permanent closuremember (e.g., seams, heat bonds, pressure welds, adhesives, cohesivebonds, mechanical fasteners, etc.). A pant can be preformed anywherealong the circumference of the article in the waist region (e.g., sidefastened or seamed, front waist fastened or seamed, rear waist fastenedor seamed).

The present disclosure relates to methods and apparatuses for assemblingabsorbent articles, and in particular, to methods and apparatuses forassembling disposable pant diapers having one or more contoured elasticbelts. The diapers may each include a chassis connected with front andback elastic belts. The chassis may include a topsheet, a backsheet, andan absorbent core disposed between the topsheet and the backsheet. Thechassis may also have a first end region and an opposing second endregion separated from each other by a central region. During theassembly process, opposing end regions of the chassis are connected withthe elastic belts in the form of first and second continuous elasticlaminates. The chassis are then folded to place the elastic laminatesinto a facing relationship. Once the chassis are folded, the innerlongitudinal edges of one or both the elastic laminates are then cut todefine a contoured shape. As discussed in more detail below, discretepieces of trim material may be removed from one or both the elasticlaminates along inner longitudinal edges, and the first and secondcontinuous elastic laminates are cut in the cross direction to formdiscrete pant diapers. In some configurations, a single knife bothremoves the trim material and cuts the elastic laminates in crossdirection. While in other configurations, a first knife removes the trimmaterial and a second knife cuts the elastic laminates in crossdirection. In such process configurations, the required handling of theshaped elastic laminates is minimized, because contouring of the elasticbelts is performed near the end of the diaper assembly process.

As previously mentioned, the processes and apparatuses discussed hereinmay be used in the manufacture of different types of absorbent articles.To help provide additional context to the subsequent discussion of theprocess embodiments, the following provides a general description ofabsorbent articles in the form of diaper pants that include beltsubstrates that may be cut in accordance with the methods andapparatuses disclosed herein.

FIGS. 1A, 1B, and 2 show an example of a diaper pant 100 that may beassembled and folded in accordance with the apparatuses and methodsdisclosed herein. In particular, FIGS. 1A and 1B show perspective viewsof a diaper pant 100 in a pre-fastened configuration, and FIG. 2 shows aplan view of the diaper pant 100 with the portion of the diaper thatfaces away from a wearer oriented toward the viewer. The diaper pant 100shown in FIGS. 1A, 1B, and 2A includes a chassis 102 and a ring-likeelastic belt 104. As discussed below in more detail, a first elasticbelt 106 and a second elastic belt 108 are bonded together to form thering-like elastic belt 104. Although only the second elastic belt 108 isshown with a contoured or shaped edge, it is to be appreciated thateither or both the first elastic belt 106 and second elastic belt 108may include shaped edges made in accordance with the apparatuses andprocesses herein.

With continued reference to FIG. 2 , the chassis 102 includes a firstwaist region 116, a second waist region 118, and a crotch region 120disposed intermediate the first and second waist regions. The firstwaist region 116 may be configured as a front waist region, and thesecond waist region 118 may be configured as back waist region. In someembodiments, the length of each of the front waist region, back waistregion, and crotch region may be ⅓ of the length of the absorbentarticle 100. The diaper 100 may also include a laterally extending frontwaist edge 121 in the front waist region 116 and a longitudinallyopposing and laterally extending back waist edge 122 in the back waistregion 118. To provide a frame of reference for the present discussion,the diaper 100 and chassis 102 of FIG. 2 are shown with a longitudinalaxis 124 and a lateral axis 126. In some embodiments, the longitudinalaxis 124 may extend through the front waist edge 121 and through theback waist edge 122. And the lateral axis 126 may extend through a firstlongitudinal or right side edge 128 and through a midpoint of a secondlongitudinal or left side edge 130 of the chassis 102.

As shown in FIGS. 1A, 1B, and 2 , the diaper pant 100 may include aninner, body facing surface 132, and an outer, garment facing surface134. The chassis 102 may include a backsheet 136 and a topsheet 138. Thechassis 102 may also include an absorbent assembly 140, including anabsorbent core 142, disposed between a portion of the topsheet 138 andthe backsheet 136. As discussed in more detail below, the diaper 100 mayalso include other features, such as leg elastics and/or leg cuffs toenhance the fit around the legs of the wearer.

As shown in FIG. 2 , the periphery of the chassis 102 may be defined bythe first longitudinal side edge 128, a second longitudinal side edge130, a first laterally extending end edge 144 disposed in the firstwaist region 116, and a second laterally extending end edge 146 disposedin the second waist region 118. Both side edges 128 and 130 extendlongitudinally between the first end edge 144 and the second end edge146. As shown in FIG. 2 , the laterally extending end edges 144 and 146are located longitudinally inward from the laterally extending frontwaist edge 121 in the front waist region 116 and the laterally extendingback waist edge 122 in the back waist region 118. When the diaper pant100 is worn on the lower torso of a wearer, the front waist edge 121 andthe back waist edge 122 of the chassis 102 may encircle a portion of thewaist of the wearer. At the same time, the chassis side edges 128 and130 may encircle at least a portion of the legs of the wearer. And thecrotch region 120 may be generally positioned between the legs of thewearer with the absorbent core 142 extending from the front waist region116 through the crotch region 120 to the back waist region 118.

It is to also be appreciated that a portion or the whole of the diaper100 may also be made laterally extensible. The additional extensibilitymay help allow the diaper 100 to conform to the body of a wearer duringmovement by the wearer. The additional extensibility may also help, forexample, the user of the diaper 100, including a chassis 102 having aparticular size before extension, to extend the front waist region 116,the back waist region 118, or both waist regions of the diaper 100and/or chassis 102 to provide additional body coverage for wearers ofdiffering size, i.e., to tailor the diaper to an individual wearer. Suchextension of the waist region or regions may give the absorbent articlea generally hourglass shape, so long as the crotch region is extended toa relatively lesser degree than the waist region or regions, and mayimpart a tailored appearance to the article when it is worn.

As previously mentioned, the diaper pant 100 may include a backsheet136. The backsheet 136 may also define the outer surface 134 of thechassis 102. The backsheet 136 may be impervious to fluids (e.g.,menses, urine, and/or runny feces) and may be manufactured from a thinplastic film, although other flexible liquid impervious materials mayalso be used. The backsheet 136 may prevent the exudates absorbed andcontained in the absorbent core from wetting articles which contact thediaper 100, such as bedsheets, pajamas and undergarments. The backsheet136 may also comprise a woven or nonwoven material, polymeric films suchas thermoplastic films of polyethylene or polypropylene, and/or amulti-layer or composite materials comprising a film and a nonwovenmaterial (e.g., having an inner film layer and an outer nonwoven layer).The backsheet may also comprise an elastomeric film. An examplebacksheet 140 may be a polyethylene film having a thickness of fromabout 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). Exemplarypolyethylene films are manufactured by Clopay Corporation of Cincinnati,Ohio, under the designation BR-120 and BR-121 and by Tredegar FilmProducts of Terre Haute, Ind., under the designation XP-39385. Thebacksheet 136 may also be embossed and/or matte-finished to provide amore clothlike appearance. Further, the backsheet 136 may permit vaporsto escape from the absorbent core (i.e., the backsheet is breathable)while still preventing exudates from passing through the backsheet 136.The size of the backsheet 136 may be dictated by the size of theabsorbent core 142 and/or particular configuration or size of the diaper100.

Also described above, the diaper pant 100 may include a topsheet 138.The topsheet 138 may also define all or part of the inner surface 132 ofthe chassis 102. The topsheet 138 may be compliant, soft feeling, andnon-irritating to the wearer's skin. It may be elastically stretchablein one or two directions. Further, the topsheet 138 may be liquidpervious, permitting liquids (e.g., menses, urine, and/or runny feces)to penetrate through its thickness. A topsheet 138 may be manufacturedfrom a wide range of materials such as woven and nonwoven materials;apertured or hydroformed thermoplastic films; apertured nonwovens,porous foams; reticulated foams; reticulated thermoplastic films; andthermoplastic scrims. Woven and nonwoven materials may comprise naturalfibers such as wood or cotton fibers; synthetic fibers such aspolyester, polypropylene, or polyethylene fibers; or combinationsthereof. If the topsheet 138 includes fibers, the fibers may bespunbond, carded, wet-laid, meltblown, hydroentangled, or otherwiseprocessed as is known in the art.

Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Aperturedfilm topsheets may be pervious to bodily exudates, yet substantiallynon-absorbent, and have a reduced tendency to allow fluids to pass backthrough and rewet the wearer's skin. Exemplary apertured films mayinclude those described in U.S. Pat. Nos. 5,628,097; 5,916,661;6,545,197; and 6,107,539.

As mentioned above, the diaper pant 100 may also include an absorbentassembly 140 that is joined to the chassis 102. As shown in FIG. 2 , theabsorbent assembly 140 may have a laterally extending front edge 148 inthe front waist region 116 and may have a longitudinally opposing andlaterally extending back edge 150 in the back waist region 118. Theabsorbent assembly may have a longitudinally extending right side edge152 and may have a laterally opposing and longitudinally extending leftside edge 154, both absorbent assembly side edges 152 and 154 may extendlongitudinally between the front edge 148 and the back edge 150. Theabsorbent assembly 140 may additionally include one or more absorbentcores 142 or absorbent core layers. The absorbent core 142 may be atleast partially disposed between the topsheet 138 and the backsheet 136and may be formed in various sizes and shapes that are compatible withthe diaper. Exemplary absorbent structures for use as the absorbent coreof the present disclosure are described in U.S. Pat. Nos. 4,610,678;4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprises primarilyabsorbent gelling material in amounts of at least about 60%, 70%, 80%,85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 and 2004/0097895.

As previously mentioned, the diaper 100 may also include elasticized legcuffs 156. It is to be appreciated that the leg cuffs 156 can be and aresometimes also referred to as leg bands, side flaps, barrier cuffs,elastic cuffs or gasketing cuffs. The elasticized leg cuffs 156 may beconfigured in various ways to help reduce the leakage of body exudatesin the leg regions. Example leg cuffs 156 may include those described inU.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115;4,909,803; and U.S. Patent Publication No. 2009/0312730A1.

As mentioned above, diaper pants may be manufactured with a ring-likeelastic belt 104 and provided to consumers in a configuration whereinthe front waist region 116 and the back waist region 118 are connectedto each other as packaged, prior to being applied to the wearer. Assuch, diaper pants may have a continuous perimeter waist opening 110 andcontinuous perimeter leg openings 112 such as shown in FIGS. 1A and 1B.

As previously mentioned, the ring-like elastic belt 104 is defined by afirst elastic belt 106 connected with a second elastic belt 108. Asshown in FIG. 2 , the first elastic belt 106 defines first and secondopposing end regions 106 a, 106 b and a central region 106 c, and thesecond elastic 108 belt defines first and second opposing end regions108 a, 108 b and a central region 108 c. The central region 106 c of thefirst elastic belt is connected with the first waist region 116 of thechassis 102, and the central region 108 c of the second elastic belt 108is connected with the second waist region 116 of the chassis 102. Asshown in FIGS. 1A and 1B, the first end region 106 a of the firstelastic belt 106 is connected with the first end region 108 a of thesecond elastic belt 108 at first side seam 178, and the second endregion 106 b of the first elastic belt 106 is connected with the secondend region 108 b of the second elastic belt 108 at second side seam 180to define the ring-like elastic belt 104 as well as the waist opening110 and leg openings 112.

As shown in FIGS. 2, 3A, and 3B, the first elastic belt 106 also definesan outer lateral edge 107 a and an inner lateral edge 107 b, and thesecond elastic belt 108 defines an outer lateral edge 109 a and an innerlateral edge 109 b. The outer lateral edges 107 a, 107 b may also definethe front waist edge 120 and the laterally extending back waist edge122. The first elastic belt and the second elastic belt may also eachinclude an outer, garment facing layer 162 and an inner, wearer facinglayer 164. It is to be appreciated that the first elastic belt 106 andthe second elastic belt 108 may comprise the same materials and/or mayhave the same structure. In some embodiments, the first elastic belt 106and the second elastic belt may comprise different materials and/or mayhave different structures. It should also be appreciated that the firstelastic belt 106 and the second elastic belt 108 may be constructed fromvarious materials. For example, the first and second belts may bemanufactured from materials such as plastic films; apertured plasticfilms; woven or nonwoven webs of natural materials (e.g., wood or cottonfibers), synthetic fibers (e.g., polyolefins, polyamides, polyester,polyethylene, or polypropylene fibers) or a combination of naturaland/or synthetic fibers; or coated woven or nonwoven webs. In someembodiments, the first and second elastic belts include a nonwoven webof synthetic fibers, and may include a stretchable nonwoven. In otherembodiments, the first and second elastic belts include an innerhydrophobic, non-stretchable nonwoven material and an outer hydrophobic,non-stretchable nonwoven material.

The first and second elastic belts 106, 108 may also each include beltelastic material interposed between the outer layer 162 and the innerlayer 164. The belt elastic material may include one or more elasticelements such as strands, ribbons, films, or panels extending along thelengths of the elastic belts. As shown in FIGS. 2, 3A, and 3B, the beltelastic material may include a plurality of elastic strands 168 whichmay be referred to herein as outer, waist elastics 170 and inner, waistelastics 172. As shown in FIG. 2 , the elastic strands 168 continuouslyextend laterally between the first and second opposing end regions 106a, 106 b of the first elastic belt 106 and between the first and secondopposing end regions 108 a, 108 b of the second elastic belt 108. Insome embodiments, some elastic strands 168 may be configured withdiscontinuities in areas, such as for example, where the first andsecond elastic belts 106, 108 overlap the absorbent assembly 140. Insome embodiments, the elastic strands 168 may be disposed at a constantinterval in the longitudinal direction. In other embodiments, theelastic strands 168 may be disposed at different intervals in thelongitudinal direction. The belt elastic material in a stretchedcondition may be interposed and joined between the uncontracted outerlayer and the uncontracted inner layer. When the belt elastic materialis relaxed, the belt elastic material returns to an unstretchedcondition and contracts the outer layer and the inner layer. The beltelastic material may provide a desired variation of contraction force inthe area of the ring-like elastic belt. It is to be appreciated that thechassis 102 and elastic belts 106, 108 may be configured in differentways other than as depicted in FIG. 2 .

In some configurations, the first elastic belt 106 and/or second elasticbelt 108 may define curved contours. For example, as shown in FIG. 2 ,the inner lateral edge 109 b of the second elastic belt 108 may includenon-linear or curved portions 109 c in the first and second opposing endregions 108 a, 108 b. Such curved contours may help define desiredshapes to leg opening 112, such as for example, relatively rounded legopenings. Although the inner lateral edge 107 b of the first elasticbelt is depicted as being a straight line, it is to be appreciated thatthe inner lateral edge 107 b may also include curved portions in thefirst and second opposing end regions 106 a, 106 b. In addition tohaving curved contours, the elastic belts 106, 108 may include elasticstrands 168, 172 that extend along non-linear or curved paths that maycorrespond with the curved contours of the inner lateral edges 107 b,109 b. As discussed below, such non-linear or curved contours may beapplied to the inner lateral edges 107 b, 109 b with the methods andapparatuses herein.

As previously mentioned, the apparatuses and methods according to thepresent disclosure may be utilized to assemble various components ofpre-fastened, refastenable pant diapers 100. For example, FIG. 4 shows aschematic view of a converting apparatus 300 adapted to manufacture pantdiapers 100. The method of operation of the converting apparatus 300 maybe described with reference to the various components of pant diapers100 described above and shown in FIGS. 1A, 1B, and 2 . Although thefollowing methods are provided in the context of the diaper 100 shown inFIGS. 1A, 1B, and 2 , it is to be appreciated that various embodimentsof diaper pants can be manufactured according to the methods disclosedherein, such as for example, the absorbent articles disclosed in U.S.Pat. No. 7,569,039; U.S. Patent Publication Nos. 2005/0107764A1,2012/0061016A1, and 2012/0061015A1, which are all hereby incorporated byreference herein.

As described in more detail below, the converting apparatus 300 shown inFIG. 4 operates to advance discrete chassis 102 along a machinedirection MD such that the lateral axis of each chassis 102 is parallelwith the machine direction, and wherein the chassis 102 are spaced apartfrom each other along the machine direction. Opposing waist regions 116,118 of the spaced apart chassis 102 are then connected with continuouslengths of advancing first and second elastic belt laminates 406, 408.The chassis 102 are then folded along the lateral axis to bring thefirst and second elastic belt laminates 406, 408 into a facingrelationship, and the first and second elastic belt laminates are bondedtogether with bonds 336. As discussed in more detail below, the firstand second elastic belt laminates may be bonded together with adjacentbonds 336 a, 336 b intermittently spaced along the machine direction.Each bond 336 a, 336 b may be a discrete bond site extendingcontiguously in the cross direction across a width of the first andsecond elastic belt laminates and/or may include a plurality ofrelatively small, discrete bond sites arranged in the cross direction.Next, discrete pieces of trim material are removed regions of the firstand/or second elastic belt laminates 406, 408 extending between adjacentfolded chassis. The first and second continuous elastic laminates 406,408 are cut in the cross direction between adjacent bonds 336 a, 336 bto create discrete pant diapers 100, such as shown in FIGS. 1A and 1B.

As shown in FIG. 4 , a first continuous substrate layer in the form of acontinuous length of outer layer belt material 162; a second continuoussubstrate layer in the form of a continuous length of inner layer beltmaterial 164; and elastics 168 are combined to form a continuous elasticlaminate in the form of a belt material 402. More particularly,continuous lengths of outer layer belt material 162, inner layer beltmaterial 164, outer elastic strands 170 and inner elastic strands 172are advanced in a machine direction MD and combined at nip rolls 502 toform a continuous length of belt material 402. Before entering the niprolls 502, the outer elastic strands 170 and inner elastic strands 172are stretched in the machine direction MD. In addition, adhesive 504 mayapplied to the elastic strands 170, 172 as well as either or both of thecontinuous lengths of outer layer belt material 162 and inner layer beltmaterial 164 before entering nip rolls 502. Further, adhesive 504 may beapplied intermittently along the lengths of the inner elastic strands172 and/or intermittently along the length of either or both of thecontinuous lengths of outer layer belt material 162 and inner layer beltmaterial 164 before entering nip rolls 502. As such, the inner elasticstrands 172 may be intermittently bonded to either or both of thecontinuous lengths of outer layer belt material 162 and inner layer beltmaterial 164 along the machine direction MD. Thus, the belt material 402may include non-bonded regions intermittently spaced between bondedregions along the machine direction MD, wherein the inner elasticstrands 172 are not bonded to either the outer layer belt material 162or inner layer belt material 164 in the non-bonded regions. And theinner elastic strands 172 are bonded to the outer layer belt material162 and/or inner layer belt material 164 in the bonded regions. AlthoughFIG. 4 shows an embodiment wherein the belt material 402 is formed bycombining continuous lengths of outer layer belt material 162 and innerlayer belt material 164 with elastic strands 168, it is to beappreciated the belt material 402 can be formed in various ways, such asdisclosed in U.S. Pat. No. 8,440,043 and U.S. Patent Publication Nos.US2013/0255861A1; US2013/0255862A1; US2013/0255863A1; US2013/0255864A1;and US2013/0255865A1.

Referring back to FIG. 4 , from the nip rolls 502 the continuous lengthof belt material 402 advances in the machine direction MD to a cutter506 that cuts the belt material 402 into two continuous belt substrates,referred to as a first belt substrate 406 and a second belt substrate408. The cutter 506 may be configured in various ways. For example, insome embodiments the cutter 506 may be a slitter or a die cutter thatseparates the belt material into two continuous belt substrates witheither a straight line cut and/or a curved line cut. The cutter 506 mayalso be configured as a perforator that perforates the belt materialwith a line of weakness and wherein the belt material is separated alongthe line of weakness in a later step. From the cutter 506, the first andsecond belt substrates 406, 408 advance through a diverter 508 thatseparates the first and second belt substrates from each other in thecross direction CD, such as shown in FIG. 5B. The elastic strands 170,172, and thus, the continuous length of first and second belt substrates406, 408 are maintained in a stretched condition while advancing alongthe machine direction MD. It is to be appreciated that the diverter 508may be configured in various ways. For example, in some embodiments, thediverter 508 may include turn bars angled at 45 degrees or some otherangle with respect to the machine direction. In some embodiments, thediverter may include cambered rollers. Other embodiments may includediverters in the form of a pivot table, such as, for example, theFIFE-500 Web Guiding System, by Maxcess-FIFE Corporation. The divertermay also include instrumentation and web edge control features thatallow for precise active control of the substrate positions.

As shown in FIG. 5C, the first belt substrate 406 includes an outerlongitudinal edge 107 a and an inner longitudinal edge 107 b defining asubstantially constant width, W1, in a cross direction. And the secondbelt substrate 408 includes an outer longitudinal edge 109 a and aninner longitudinal edge 109 b defining a substantially constant width,W2, in a cross direction, wherein W2 is greater than W1. It is to beappreciated that in some configurations, W1 may be equal to or greaterthan W2. As previously mentioned, the first belt substrate 406 isseparated in the cross direction from the second belt substrate 408 todefine a gap between the inner longitudinal edge 107 b of the first beltsubstrate 406 and the inner longitudinal edge 109 b of the second beltsubstrate 408. As discussed in more detail below, the first and secondbelt substrates 406, 408 advance from the diverter 508 to a nip 316between the carrier apparatus 308 and a carrier apparatus 318 to becombined with discrete chassis 102.

As shown in FIGS. 4 and 5A, a continuous length of chassis assemblies302 are advanced in a machine direction MD to a carrier apparatus 308and cut into discrete chassis 102 with knife roll 306. The continuouslength of chassis assemblies may include absorbent assemblies 140sandwiched between topsheet material 138 and backsheet material 136, legelastics, barrier leg cuffs and the like. As shown in FIG. 5A, portionof the chassis assembly is cut-away to show a portion of the topsheetmaterial 138 and an absorbent assembly 140.

After the discrete absorbent chassis 102 are cut by the knife roll 306,the carrier apparatus 308 rotates and advances the discrete chassis 102in the machine direction MD in the orientation shown in FIG. 5B1,wherein the longitudinal axis 124 of the chassis 102 is generallyparallel with the machine direction MD. While the chassis 102 shown inFIG. 5B1 is shown with the second laterally extending end edge 146 as aleading edge and the first laterally extending end edge 144 as thetrailing edge, it is to be appreciated that in other embodiments, thechassis 102 may be advanced in other orientations. For example, thechassis may be oriented such that the second laterally extending endedge 146 is a trailing edge and the first laterally extending end edge144 is a leading edge. The carrier apparatus 308 also rotates while atthe same time changing the orientation of the advancing chassis 102. Thecarrier apparatus 308 may also change the speed at which the chassis 102advances in the machine direction MD. It is to be appreciated thatvarious forms of carrier apparatuses may be used with the methodsherein, such as for example, the carrier apparatuses disclosed in U.S.Pat. No. 7,587,966. FIG. 5B2 shows the orientation of the chassis 102 onthe carrier apparatus 308 while advancing in the machine direction. Moreparticularly, FIG. 5B2 shows the chassis 102 with the lateral axis 126of the chassis 102 generally parallel with the machine direction MD, andwherein the second longitudinal side edge 130 is the leading edge andthe first longitudinal side edge 128 is the trailing edge.

As discussed below with reference to FIGS. 4, 5C, 5D, 5E, and 5F, thechassis 102 are transferred from the carrier apparatus 308 and combinedwith advancing, continuous lengths of belt laminates 406, 408, which aresubsequently cut to form first and second elastic belts 106, 108 ondiapers 100.

With reference to FIGS. 4 and 5C, the chassis 102 are transferred fromthe carrier apparatus 308 to a nip 316 between the carrier apparatus 308and a carrier apparatus 318 where the chassis 102 is combined withcontinuous lengths of advancing front belt 406 and back belt 408substrate material. The front belt laminate material 406 and the backbelt laminate material 408 each define a wearer facing surface 312 andan opposing garment facing surface 314. The wearer facing surface 312 ofthe first belt laminate 406 may be combined with the garment facingsurface 134 of the chassis 102 along the first waist region 116, and thewearer facing surface 312 of the second belt laminate 408 may becombined with the garment facing surface 134 of the chassis 102 alongthe second waist region 118. As shown in FIG. 4 , adhesive 320 may beintermittently applied to the wearer facing surface 312 of the first andsecond belt laminates 406, 408 before combining with the discretechassis 102 at the nip 316 between roll 318 and the carrier apparatus308.

With reference to FIGS. 4 and 5D, a continuous length of absorbentarticles 400 are defined by multiple discrete chassis 102 spaced fromeach other along the machine direction MD and connected with each otherby the second belt laminate 408 and the first belt laminate 406. Asshown in FIG. 4 , the continuous length of absorbent articles 400advances from the nip 316 to a folding apparatus 332. At the foldingapparatus 332, each chassis 102 is folded in the cross direction CDalong a lateral axis 126 to place the first waist region 116, andspecifically, the inner, body facing surface 132 into a facing, surfaceto surface orientation with the inner, body surface 132 of the secondwaist region 118. The folding of the chassis also positions the wearerfacing surface 312 of the second belt laminate 408 extending betweeneach chassis 102 in a facing relationship with the wearer facing surface312 of the first belt laminate 406 extending between each chassis 102.As shown in FIGS. 4, 5D, and 5E, the folded discrete chassis 102connected with the first and second belt laminates 406, 408 are advancedfrom the folding apparatus 332 to a bonder apparatus 334. The bonderapparatus 334 operates to bond an overlap area 362, thus creatingdiscrete bonds 336 a, 336 b. The overlap area 362 includes a portion ofthe second belt laminate 408 extending between each chassis 102 and aportion of the first belt laminate 406 extending between each chassis102.

As previously mentioned, the first belt laminate 406 may define a firstwidth, W1, in the cross direction CD and the second belt laminate maydefine a second width, W2, in the cross direction CD, wherein W2 isgreater than W1. Thus, as shown in FIGS. 5E and 5E1, folding eachchassis 102 and positioning the first belt laminate 406 into a facingrelationship with the second belt laminate 408 may define uncoveredregions 410 of the second belt laminate 408 intermittently spacedbetween the chassis 102 along the machine direction MD. The uncoveredregions 410 may have a width, W3, extending in the cross directiondefined by a distance extending between the inner longitudinal edge 107b of the first belt laminate 406 and the inner longitudinal edge 109 bof the second belt laminate 408. It is to be appreciated that foldingeach chassis 102 and positioning the first belt laminate 406 into afacing relationship with the second belt laminate 408 may also includealigning the outer longitudinal edge 107 a of the first belt laminate406 with the outer longitudinal edge 109 a of the second belt laminate408.

As shown in FIGS. 4 and 5F, the continuous length of absorbent articles400 are advanced from the bonder 334 to a cutting apparatus 338 wherethe first belt laminate 406 and the second belt laminate 408 are cutalong the cross direction CD between adjacent bonds 336 a, 336 b tocreate discrete absorbent articles 100. As such, bond 336 a maycorrespond with and form a first side seam 178 on an absorbent article100, and the bond 336 b may correspond with and form a second side seam180 on a subsequently advancing absorbent article.

In addition to cutting the first belt laminate 406 and the second beltlaminate 408 along the cross direction CD between adjacent bonds 336 a,336 b, the cutting apparatus 338 may also be configured to removediscrete pieces of trim material 412 from the uncovered regions 410 ofthe second belt laminate 408, such as shown in FIGS. 5E1 and 5F1. Asshown in FIG. 5E1, the cutting apparatus 338 may be configured to cutthe first and second belt laminates 406, 408 along a first cut line 414and a second cut line 416. The first cut line 414 may extend in a crossdirection CD to sever the first and second belt laminates 406, 408. Andthe second cut line may extend in the machine direction and crossdirection to sever the pieces of trim material 412 from the first beltlaminate 406 and/or the second belt laminate 408. As such, the cuttingapparatus 338 may be configured to cut discrete absorbent articles 100from the continuous length of absorbent articles 400 while at the sametime forming contoured and/or shaped front and/or back elastic belts106, 108 on the absorbent articles 100. As discussed below, theprocesses and apparatuses herein may be configured to produce absorbentarticles 100 having a front elastic belt 106 with a substantiallyconstant width and a back elastic belt 108 having a variable widthdefined by a contoured or shaped edge 109 b.

It is to be appreciated that that the first and second cut lines may beconfigured in various ways. For example, as shown in FIGS. 5E1 and 5F1,the first cut line 414 may extend in a straight line in the crossdirection CD to intersect with the second cut line 416. The second cutline may extend in a curved path to define a length TL in the machinedirection MD. As shown in FIG. 5E1, the adjacent chassis 102 may beseparated from each other in the machine direction MD by a distance D,and as such, the second cut line 416 may have a length TL that is equalto or less then the distance D such that the chassis 102 are not cutwhile removing the trim material 412. However, in some embodiments, thelength TL may be greater than the distance D. The second cut line 416may also intersect with and extend in the cross direction CD from theinner longitudinal edge 107 b and/or inner longitudinal edge 109 b ofthe first and/or second belt laminates 406, 408. For example, as shownin FIG. 5E1, the second cut line 416 extends in the cross direction CDfrom the inner longitudinal edge 109 b of the second belt laminate 408 adistance TW to intersect with the first cut line 414. Thus, as shown inFIG. 5F1, the piece of trim material 412 may have a corresponding lengthTL and width TW.

It is to be appreciated that the first cut line 414 may extend along astraight and/or curved path along the cross direction CD. In addition,the first cut line 414 may be perpendicular with respect to the outerlongitudinal edge 107 a and/or outer longitudinal edge 109 a of thefirst and/or second belt laminates 406, 408. In some configurations, thefirst cut line 414 may be define an angle that is less than 90° withrespect to the outer longitudinal edge 107 a and/or outer longitudinaledge 109 a. In addition, it is to be appreciated that the second cutline 416 may extend along a path define by straight and/or curvedportions.

With continued reference to FIGS. 5E1 and 5F1, the cutting apparatus 338may be configured to remove trim material 412 from only the uncoveredregions 410 of the second belt laminate 408 without removing materialfrom the first belt laminate 406. For example, the first cut line 414may extend from the outer longitudinal edges 107 a, 109 a of the firstand second belt laminates 406, 408 to the inner longitudinal edge 107 bof the first belt laminate 406. And the second cut line 416 may extend adistance TW in the cross direction from the inner longitudinal edge 109b of the second belt laminate 408 to inner longitudinal edge 107 b ofthe first belt laminate 406 without crossing the inner longitudinal edge107 b. As such, in some configurations, the width TW of the trimmaterial 412 may be the equal to or substantially equal to the width W3of the uncovered region 410. In some configurations, the second cut line416 may extend a distance TW in the cross direction from the innerlongitudinal edge 109 b of the second belt laminate 408 that is lessthan the width W3 of the uncovered region 410, such as shown in FIG.5E2. And in some configurations, the second cut line 416 may extend adistance TW in the cross direction from the inner longitudinal edge 109b of the second belt laminate 408 that is greater than the width W3 ofthe uncovered region 410, such as shown in FIG. 5E3. As such, the secondcut line 416 may cross the inner longitudinal edge 107 b of the firstbelt laminate 406, and thus, the trim material 412 may include a portionof the first belt laminate 406 as well as the second belt laminate 408.

With reference to FIG. 5E4, the cutting apparatus 338 may also beconfigured to such to sever the first and second belt laminates 406, 408with a pair of cut lines 418 a, 418 b extending in the cross directionCD and diverging from each other the machine direction MD. As such, thepair of cut lines 418 a, 418 b may define a piece of trim material 412the extends in the machine direction MD between adjacent bonds 336 a,336 b as well as extending in the cross direction CD from the outerlongitudinal edges 107 a, 109 a of the first and second belt laminates406, 408 to the inner longitudinal edges 107 b, 109 b.

It is to be appreciated that the cutting apparatus 338 may be configuredin various ways. For example, as shown in FIGS. 6 and 7 , the cuttingapparatus 338 may include a cutting roll 340 and an anvil roll 342rotatably connected with a frame 344. Various types of cutting roll,anvil roll, and frame arrangements may be utilized, such as disclosedfor example in U.S. Pat. No. 7,971,525. More particularly, the cuttingroll 340 and the anvil roll 342 may be adapted to rotate in opposingdirections. And the cutting roll 340 may be positioned adjacent theanvil roll 342 to define a nip 346 therebetween. As shown in FIG. 6 ,the cutting roll 340 may include an outer circumferential surface 348,and the anvil roll 342 may include an outer circumferential surface 350.The cutting roll 340 may also include one or more blades 352. As shownin FIG. 7 , the blade 352 may include a distal edge 354 having a firstportion 354 a that extends in the cross direction CD and a secondportion 354 b that extends in the machine direction MD and crossdirection CD. As such, the first portion 354 a of the distal edge 354may correspond with the first cut line 414 discussed above, and thesecond portion 354 b of the distal edge 354 may correspond with thesecond cut line 416 discussed above. Thus, in operation, a continuouslength of absorbent articles 400 may advance in the machine direction MDthrough the nip 346 between the rotating cutting roll 340 and anvil roll342. And the distal edge 354 of the blade 352 presses the first andsecond belt substrates 406 and 408 against the outer circumferentialsurface 350 of the anvil roll 350 to separate or cut discrete absorbentarticles 100 from the continuous length of absorbent articles 400, whileat the same time removing discrete pieces of trim material 412 to formcontoured and/or shaped front and/or back elastic belts 106, 108 on theabsorbent articles 100.

The processes and apparatuses herein may also be configured in variousways to remove the pieces of trim material 412 from the cuttingapparatus 338. In some configurations, the cutting roll and/or anvilroll may be configured as a cantilevered unit where the open cuttingroll end of the cantilevered unit is used for the trim removal. Forexample, as shown in FIG. 6 , a vacuum system 356 may be fluidlyconnected with the cutting roll 340 to pull pieces of trim material 412from the cutting roll 340. More particularly, as shown in FIGS. 6 and 7, the cutting roll 340 may include an aperture 358 in the outercircumferential surface 348 adjacent the blade 352. In turn, theaperture may be fluidly connected to a channel 360 extending through theinterior of the cutting roll 340, wherein the channel 360 is fluidlyconnected with the vacuum system 356. During operation, the vacuumsystem 356 may pull the cut pieces of trim material 412 through theaperture 358 in the cutting roll 340 and the through the channel 360from inside in the cutting roll 340. As shown in FIG. 7 , the aperture358 may have perimeter that defines a shape that is substantially thesame as the pieces of trim material 412. In addition, because the beltlaminates being cut may include stretched elastic strands, the trimmaterial may contract in the in the width and length directions whilebeing cut. As such, the contraction in size of the trim material mayhelp the trim material pass through aperture relatively easier. Also,upon separation of the elastic strands will help promote the separationof cut or partially cut nonwoven fibers.

It is to be appreciated that the cutting roll 340 may be configured invarious ways. For example, in some embodiments, the cutting roll 340 maybe configured so as to cut one product contour per revolution. Such aconfiguration may allow the vacuum system to remain turned on during theentire cutting cycle, whereas cutting roll configured to cut more thanone product per revolution may require an on/off cycle for the vacuumsystem.

In some embodiments, the cutting roll 340 may include bearer rings andthe distal edge of the blade is smaller in diameter than the diameter ofthe bearer ring, which reduce the tendency to vibrate due to theimbalance of cutting force during the crosscut. In some embodiments, thediameter of the distal cutting edge may be about 1 to 10 micron smallerin diameter than the bearer ring. In some embodiments, the cutting rollmay be configured such that the diameter defined by the distal edge ofthe blade is equal to or greater than the diameter of the bearer ring.

As previously mentioned, the processes and apparatuses herein may alsobe configured in various ways to remove the pieces of trim material 412from the cutting apparatus 338. In some configurations, the cuttingapparatus 338 may be configured such that the pieces of trim material412 are removed from an outer surface 348, 350 of the cutting roll 340and/or anvil roll 342 after cutting discrete absorbent articles 100 fromthe continuous length of absorbent articles 400. For example, as shownin FIG. 8 , a first carrier 370 advances a continuous length ofabsorbent articles 400 in a machine direction MD to the cuttingapparatus 338. In particular, the first carrier 370 includes a firstconveyor 372 and a second conveyor 374, and the continuous length ofabsorbent articles 400 is advanced in a first direction 376 between thefirst and second conveyors 372, 374 to the nip 346 between the kniferoll 340 and the anvil roll 342. As discussed above, the cuttingapparatus 338 simultaneously cuts the second belt laminate 408 and thefirst belt laminate 406 to form discrete absorbent articles 100 from thecontinuous length of absorbent articles 400 while also cutting pieces oftrim material 412 to form contoured and/or shaped front and/or backelastic belts 106, 108 on the absorbent articles 100. The discreteabsorbent articles 100 are then transferred from the cutting apparatus338 to a second carrier 378. The second carrier 378 includes a firstconveyor 380 and a second conveyor 382, and the discrete absorbentarticles 100 are advanced in a second direction 384 between the firstand second conveyors 380, 382 from the cutting apparatus 338.

The pieces of trim material 412 may be removed from the cuttingapparatus after the cutting apparatus 338 cuts discrete absorbentarticles 100 from the continuous length of absorbent articles 400. Forexample, as shown in FIG. 8 , the pieces of trim material 412 may betemporarily held onto the outer circumferential surface 348 of the kniferoll 340. As the knife roll 340 rotates, the trim material 412 iscarried away from the nip 346 and may be transferred to a trim chute 386adjacent the knife roll for subsequent disposal and/or recyclingprocesses. It is to be appreciated that the knife roll 340 may beconnected with a vacuum system to temporarily hold the trim material inposition until the trim material 412 is transferred to the trim chute386. In addition, the trim chute 386 may be connected with a vacuumsystem to help remove the trim material 412 from the knife roll 340.

As shown in FIG. 8 , the cutting apparatus 338 may be configured suchthat the discrete absorbent articles are partially wrapped and held onthe outer circumferential surface 348 of the knife roll 340 whileadvancing from the nip 346 to the second carrier 378. Holding theabsorbent articles 100 in position on the outer surface 348 of the kniferoll 340 after cutting may help prevent elastic materials that are cutunder tension from retracting. Although the cutting apparatus 338 shownin FIG. 8 is configured to temporarily hold the trim material 412 and/orthe discrete absorbent articles 100 on the knife roll 340, it is to beappreciated that the cutting apparatus 338 may configured to temporarilyhold the trim material 412 and/or discrete absorbent articles 100 on theanvil roll 342.

With continued reference to FIG. 8 , the advancement of the continuouslength of absorbent articles 400 in the first direction 376 on the firstcarrier 370 defines a first article transport plane 388 along which theabsorbent articles 400 are transported. And the advancement of thediscrete absorbent articles 100 in the second direction 384 on thesecond carrier 378 defines a second article transport plane 390 alongwhich the absorbent articles 100 are transported. It is to beappreciated that the first direction 376 and second direction 384 may bethe same or different. As such, a transfer angle 392 may be defined bythe intersection of the first and second transport planes 388, 390. Itis to be appreciated that the first and second carriers may be alignedin various ways to define various sizes of transfer angles 392. Forexample, in some embodiments, the transfer angle 392 may be from 90degrees to 180 degrees.

Although the cutting apparatus 338 may be configured to cut discreteabsorbent articles 100 from the continuous length of absorbent articles400 while at the same time forming contoured and/or shaped front and/orback elastic belts 106, 108 on the absorbent articles 100, it is to beappreciated that the process and apparatuses herein may be configured toperform these steps at different times. For example, the process may beconfigured with a separate trim removal unit forms the contoured and/orshaped front and/or back elastic belts 106, 108 on the absorbentarticles 100 before cutting discrete absorbent articles 100 from thecontinuous length of absorbent articles 400. In some embodiments, theseparate trim removal or contouring cut may be performed after theapparatus 334 operates to bond an overlap area 362, thus creatingdiscrete bonds 336 a, 336 b. In other embodiments, the separate trimremoval or contouring cut may be performed after the folding apparatus332 folds the chassis also positions the wearer facing surface 312 ofthe second belt laminate 408 extending between each chassis 102 in afacing relationship with the wearer facing surface 312 of the first beltlaminate 406 extending between each chassis 102, and before theapparatus 334 operates to bond an overlap area 362, thus creatingdiscrete bonds 336 a, 336 b.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for assembling disposable pant diapers,each pant diaper comprising a chassis having a first end region and anopposing second end region separated from each other by a centralregion, and having a longitudinal axis and a lateral axis, the chassiscomprising: a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet, the method comprising steps of:advancing a first continuous elastic laminate along a machine direction,the first continuous elastic laminate having an outer longitudinal edgeand an inner longitudinal edge with a constant width, W1, in a crossdirection; advancing a second continuous elastic laminate along themachine direction, the second continuous elastic laminate having anouter longitudinal edge and an inner longitudinal edge with a constantwidth, W2, in the cross direction; depositing a plurality of chassisspaced apart from each other along the machine direction onto the firstcontinuous elastic laminate and the second continuous elastic laminate,wherein the first end regions of each chassis are connected with thefirst continuous elastic laminate, and the second end regions of eachchassis are connected with the second continuous elastic laminate;folding each chassis along the lateral axis to position the firstcontinuous elastic laminate into a facing relationship with the secondcontinuous elastic laminate and forming uncovered regions of the secondcontinuous elastic laminate intermittently spaced between the chassisalong the machine direction and having a width, W3, extending in thecross direction formed by a distance extending between the innerlongitudinal edge of the first continuous elastic laminate and the innerlongitudinal edge of the second continuous elastic laminate; removingdiscrete pieces of trim material from the uncovered regions of thesecond continuous elastic laminate; and cutting the first and secondcontinuous elastic laminates in the cross direction to form discretepant diapers.
 2. The method of claim 1, further comprising a step of:advancing the first continuous elastic laminate in the facingrelationship with the second continuous elastic laminate through a nipformed between a cutting roll and an anvil roll, wherein the cuttingroll includes a blade having a distal edge extending in the crossdirection and the machine direction; and wherein the steps of removingthe discrete pieces of trim material and cutting the first and secondcontinuous elastic laminates in the cross direction further comprisepressing the distal edge of the blade against the first continuouselastic laminate and the uncovered regions of the second continuouselastic laminate.
 3. The method of claim 1, wherein the discrete piecesof the trim material each having a maximum width, TW, that is equal tothe width, W3, of the uncovered regions.
 4. The method of claim 1,wherein width, W2, of the second continuous elastic laminate is greaterthan the width, W1, of the first continuous elastic laminate.
 5. Themethod of claim 1, further comprising steps of: advancing a firstcontinuous substrate layer having a first surface and an opposing secondsurface in a machine direction, and a width in a cross direction;advancing a second continuous substrate layer having a first surface andan opposing second surface in a machine direction, and a width in across direction; advancing elastic strands in the machine direction;bonding the elastic strands between the first surface of the firstsubstrate layer and the first surface of the second substrate layer toform an elastic laminate; and cutting the elastic laminate along themachine direction to form the first continuous elastic laminate and thesecond continuous elastic laminate.
 6. The method of claim 5, whereinthe step of bonding the elastic strands further comprises intermittentlybonding the elastic strands in a stretched state between the firstsurface of the first substrate layer and the first surface of the secondsubstrate layer such that the elastic laminate includes bonded regionsand non-bonded regions intermittently spaced along the machinedirection, wherein the elastic strands are bonded to the first surfaceof the first substrate layer and the first surface of the secondsubstrate layer in the bonded regions, and wherein the elastic strandsare not bonded to the first surface of the first substrate layer and thefirst surface of the second substrate layer in the non-bonded regions.7. The method of claim 1, wherein the step of folding further comprisesaligning the outer longitudinal edge of the first continuous elasticlaminate with the outer longitudinal edge of the second continuouselastic laminate.
 8. The method of claim 1, further comprising a step ofbonding the first continuous elastic laminate with the second continuouselastic laminate at pairs of discrete bond regions separated from eachother along the machine direction.
 9. The method of claim 8, wherein thestep of cutting the first and second continuous elastic laminatesfurther comprises cutting the first and second continuous elasticlaminates between pairs of discrete bond regions.
 10. A method forassembling disposable pant diapers, each pant diaper comprising achassis having a first end region and an opposing second end regionseparated from each other by a central region, and having a longitudinalaxis and a lateral axis, the chassis comprising: a topsheet, abacksheet, and an absorbent core disposed between the topsheet and thebacksheet, the method comprising steps of: advancing a first continuouselastic laminate along a machine direction, the first continuous elasticlaminate having an outer longitudinal edge and an inner longitudinaledge with a constant width, W1, in a cross direction; advancing a secondcontinuous elastic laminate along the machine direction, the secondcontinuous elastic laminate having an outer longitudinal edge and aninner longitudinal edge with a constant width, W2, in the crossdirection, wherein the first continuous elastic laminate is separated inthe cross direction from the second continuous elastic laminate todefine a gap between the inner longitudinal edge of the first continuouselastic laminate and the inner longitudinal edge of the secondcontinuous elastic laminate; depositing a plurality of chassis spacedapart from each other along the machine direction across the gap andonto the first continuous elastic laminate and the second continuouselastic laminate, wherein the first end regions of each chassis areconnected with the first continuous elastic laminate, and the second endregions of each chassis are connected with the second continuous elasticlaminate; folding each chassis along the lateral axis to position thefirst continuous elastic laminate into a facing relationship with thesecond continuous elastic laminate; removing discrete pieces of trimmaterial simultaneously from the first continuous elastic laminate andthe second continuous elastic laminate; and cutting the first and secondcontinuous elastic laminates in the cross direction to form discretepant diapers.
 11. The method of claim 10, further comprising a step of:advancing the first continuous elastic laminate in the facingrelationship with the second continuous elastic laminate through a nipformed between a cutting roll and an anvil roll, wherein the cuttingroll includes a blade having a distal edge extending in the crossdirection and the machine direction; and wherein the steps of removingthe discrete pieces of trim material and cutting the first and secondcontinuous elastic laminates in the cross direction further comprisepressing the distal edge of the blade against the first continuouselastic laminate and the second continuous elastic laminate.
 12. Themethod of claim 10, wherein a width, W2, of the second continuouselastic laminate is greater than a width, W1, of the first continuouselastic laminate.
 13. The method of claim 10, further comprising stepsof: advancing a first continuous substrate layer having a first surfaceand an opposing second surface in a machine direction, and a width in across direction; advancing a second continuous substrate layer having afirst surface and an opposing second surface in a machine direction, anda width in a cross direction; advancing elastic strands in the machinedirection; bonding the elastic strands between the first surface of thefirst substrate layer and the first surface of the second substratelayer to form an elastic laminate; and cutting the elastic laminatealong the machine direction to form the first continuous elasticlaminate and the second continuous elastic laminate.
 14. The method ofclaim 13, wherein the step of bonding the elastic strands furthercomprises intermittently bonding the elastic strands in a stretchedstate between the first surface of the first substrate layer and thefirst surface of the second substrate layer such that the elasticlaminate includes bonded regions and non-bonded regions intermittentlyspaced along the machine direction, wherein the elastic strands arebonded to the first surface of the first substrate layer and the firstsurface of the second substrate layer in the bonded regions, and whereinthe elastic strands are not bonded to the first surface of the firstsubstrate layer and the first surface of the second substrate layer inthe non-bonded regions.
 15. The method of claim 10, wherein the step offolding further comprises aligning the outer longitudinal edge of thefirst continuous elastic laminate with the outer longitudinal edge ofthe second continuous elastic laminate.
 16. The method of claim 10,further comprising a step of bonding the first continuous elasticlaminate with the second continuous elastic laminate at pairs ofdiscrete bond regions separated from each other along the machinedirection.
 17. The method of claim 16, wherein the step of cutting thefirst and second continuous elastic laminates further comprises cuttingthe first and second continuous elastic laminates between pairs ofdiscrete bond regions.
 18. An absorbent article comprising: a firstbelt; a second belt; a chassis comprising: a topsheet, a backsheet, andan absorbent core positioned between the topsheet and the backsheet,wherein opposing end portions of the chassis are bonded with the firstbelt and the second belt; the chassis being folded along a lateral axissuch that the first belt is in a facing relationship with the back belt,and wherein opposing end portions of the first belt and the second beltare connected to define a waist opening and leg openings; and alongitudinal edge defined by a cut line, the cut line comprising a firstportion extending longitudinally through the first belt and the secondbelt and a second portion extending longitudinally and laterally throughthe first belt, the second belt, and the chassis.